John Deere A3 M-Gator Service Repair Manual Instant Download (tm115719)

1
JOHN DEERE AG TURF DIVISION
M-Gator A3 TM115719 SEPTEMBER 2011 TECHNICAL
MANUAL
North American Version Litho In U.s.a.
2
INTRODUCTION
Manual Description This technical manual is
written for an experienced technician and
contains sections that are specifically for this
product. It is a part of a total product support
program. The manual is organized so that all the
information on a particular system is kept
together. The order of grouping is as follows
Safety
Specifications and Information
Engine

• Table of Contents
• Specifications and Information
• Identification Numbers
• Tools and Materials
• Component Location
• Schematics and Harnesses
• Theory of Operation
• Operation and Diagnostics
• Diagnostics
• Tests and Adjustments
• Repair
• Other

Electrical
Power Train
Steering
Brakes
Note Depending on the particular section or
system being covered, not all of the above groups
may be used.
Miscellaneous
The bleed tabs for the pages of each section will
align with the sections listed on this page. Page
numbering is consecutive from the beginning of
the Safety section through the last section. We
appreciate your input on this manual. If you find
any errors or want to comment on the layout of
the manual please contact us.
All information, illustrations and specifications
in this manual are based on the latest
information at the time of publication. The right
is reserved to make changes at any time without
notice. COPYRIGHT 2011 Deere Co. John Deere Ag
Turf Division All rights reserved Previous
Editions COPYRIGHT
Introduction
3
SAFETY

• Store flammable fluids away from fire hazards. Do
  not incinerate or puncture pressurized
  containers.
• Make sure machine is clean of trash, grease, and
  debris.
• Do not store oily rags they can ignite and burn
  spontaneously.

Safety
Recognize Safety Information

• Be prepared if a fire starts.
• Keep a first aid kit and fire extinguisher handy.
• Keep emergency numbers for doctors, ambulance

MIF This is the safety-alert symbol. When you see
this symbol on your machine or in this manual, be
alert to the potential for personal
injury. Follow recommended precautions and safe
servicing practices.
service, hospital, and fire department near your
telephone.
Use Care In Handling And Servicing Batteries
Understand Signal Words A signal word - DANGER,
WARNING, or CAUTION - is used with the
safety-alert symbol. DANGER identifies the most
serious hazards. DANGER or WARNING safety signs
are located near specific hazards. General
precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety messages
in this manual.
MIF

• Prevent Battery Explosions
• Keep sparks, lighted matches, and open flame away
  from the top of battery. Battery gas can explode.
• Never check battery charge by placing a metal
  object across the posts. Use a volt-meter or
  hydrometer.
• Do not charge a frozen battery it may explode.
  Warm battery to 16C (60F).

Replace Safety Signs
Prevent Acid Burns

• Sulfuric acid in battery electrolyte is
  poisonous. It is strong enough to burn skin, eat
  holes in clothing, and cause blindness if
  splashed into eyes.

MIF
Replace missing or damaged safety signs. See the
machine operators manual for correct safety sign
placement.

• Avoid acid burns by
• Filling batteries in a well-ventilated area.
• Wearing eye protection and rubber gloves.
• Avoiding breathing fumes when electrolyte is
  added.
• Avoiding spilling or dripping electrolyte.
• Use proper jump start procedure.

Handle Fluids Safely - Avoid Fires Be Prepared
For Emergencies

• If you spill acid on yourself
• Flush your skin with water.
• Apply baking soda or lime to help neutralize the
  acid.
• Flush your eyes with water for 10 - 15 minutes.
• Get medical attention immediately.

MIF

• When you work around fuel, do not smoke or work
  near heaters or other fire hazards.

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5
SAFETY

• If acid is swallowed
• Drink large amounts of water or milk.
• Then drink milk of magnesia, beaten eggs, or
  vegetable oil.
• Get medical attention immediately.

Avoid Heating Near Pressurized Fluid Lines
Wear Protective Clothing
MIF Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat by
welding, soldering, or using a torch near
pressurized fluid lines or other flammable
materials. Pressurized lines can be accidentally
cut when heat goes beyond the immediate flame
area.
MIF
Service Machines Safely
Wear close fitting clothing and safety equipment
appropriate to the job. Prolonged exposure to
loud noise can cause impairment or loss of
hearing. Wear a suitable hearing protective
device such as earmuffs or earplugs to protect
against objectionable or uncomfortable loud
noises. Operating equipment safely requires the
full attention of the operator. Do not wear radio
or music headphones while operating machine.
MIF Tie long hair behind your head. Do not wear a
necktie, scarf, loose clothing, or necklace when
you work near machine tools or moving parts. If
these items were to get caught, severe injury
could result. Remove rings and other jewelry to
prevent electrical shorts and entanglement in
moving parts.
Use Care Around High-pressure Fluid Lines Avoid
High-Pressure Fluids
Support Machine Properly and Use Proper Lifting
Equipment
MIF
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid injury from
escaping fluid under pressure by stopping the
engine and relieving pressure in the system
before disconnecting or connecting hydraulic or
other lines. Tighten all connections before
applying pressure. Search for leaks with a piece
of cardboard. Protect hands and body from high
pressure fluids. If an accident occurs, see a
doctor immediately. Any fluid injected into the
skin must be surgically removed within a few
hours or gangrene may result. Doctors unfamiliar
with this type of injury should reference a
knowledgeable medical source. Such information is
available from Deere Company Medical Department
in Moline, Illinois, U.S.A.
MIF
If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on cinder
blocks, hollow tiles, or props that may crumble
under continuous load. Do not work under a
machine that is supported solely by a jack.
6
SAFETY
Follow recommended procedures in this
manual. Lifting heavy components incorrectly can
cause severe injury or machine damage. Follow
recommended procedure for removal and
installation of components in the manual.
Service Tires Safely

• Work In Clean Area
• Before starting a job
• Clean work area and machine.
• Make sure you have all necessary tools to do your
  job.
• Have the right parts on hand.
• Read all instructions thoroughly do not attempt
  shortcuts.

MIF Explosive separation of a tire and rim parts
can cause serious injury or death. Do not attempt
to mount a tire unless you have the proper
equipment and experience to perform the
job. Always maintain the correct tire pressure.
Do not inflate the tires above the recommended
pressure. Never weld or heat a wheel and tire
assembly. The heat can cause an increase in air
pressure resulting in a tire explosion. Welding
can structurally weaken or deform the wheel. When
inflating tires, use a clip-on chuck and
extension hose long enough to allow you to stand
to one side and NOT in front of or over the tire
assembly. Use a safety cage if available. Check
wheels for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.
Using High Pressure Washers Directing pressurized
water at electronic/electrical components or
connectors, bearings, hydraulic seals, fuel
injection pumps or other sensitive parts and
components may cause product malfunctions. Reduce
pressure and spray at a 45 to 90 degree angle.
Illuminate Work Area Safely Illuminate your work
area adequately but safely. Use a portable safety
light for working inside or under the machine.
Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Avoid Injury From Rotating Blades, Augers And PTO
Shafts
Work In Ventilated Area
MIF
Keep hands and feet away while machine is
running. Shut off power to service, lubricate or
remove mower blades, augers or PTO shafts.
MIF
Engine exhaust fumes can cause sickness or death.
If it is necessary to run an engine in an
enclosed area, remove the exhaust fumes from the
area with an exhaust pipe extension. If you do
not have an exhaust pipe extension, open the
doors and get outside air into the area.
7
SAFETY
Service Cooling System Safely
Park Machine Safely
MIF
MIF Explosive release of fluids from pressurized
cooling system can cause serious burns. Shut off
machine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing
completely.

• Before working on the machine
• Lower all equipment to the ground.
• Stop the engine and remove the key.
• Lock the park brake.
• Disconnect the battery ground strap.
• Hang a DO NOT OPERATE tag in operator station.

Handle Chemical Products Safely
Live With Safety
MIF
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals
used with John Deere equipment include such items
as lubricants, coolants, paints, and adhesives. A
Material Safety Data Sheet (MSDS) provides
specific details on chemical products physical
and health hazards, safety procedures, and
emergency response techniques. Check the MSDS
before you start any job using a hazardous
chemical. That way you will know exactly what the
risks are and how to do the job safely. Then
follow procedures and recommended equipment.
MIF
Before returning machine to customer, make sure
machine is functioning properly, especially the
safety systems. Install all guards and shields.
Dispose of Waste Properly Improperly disposing of
waste can threaten the environment and ecology.
Potentially harmful waste used with John Deere
equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries. Use
leakproof containers when draining fluids. Do not
use food or beverage containers that may mislead
someone into drinking from them. Do not pour
waste onto the ground, down a drain, or into any
water source. Inquire on the proper way to
recycle or dispose of waste from your local
environmental or recycling center, or from your
John Deere dealer.
8
SPECIFICATIONS AND INFORMATION
TABLE OF CONTENTS
Table of Contents General Information...........
...............................7 Metric Fastener
Torque Values ......................7 Inch
Fastener Torque Values .........................8
Face Seal Fittings with Inch Stud Ends Torque
..................................................
..........9 Face Seal Fittings with Metric Stud
Ends Torque ......................................
....................10 O-Ring Face Seal Fittings
............................11 O-Ring Boss
Fittings ....................................11 Di
esel Fuel ........................................
...........12 Diesel Fuel Lubricity
.....................................12 Diesel
Fuel Storage......................................
12 4 - Cycle Diesel Engine Oil....................
.......12 Break-In Engine Oil - Diesel
.........................13 Transaxle Oil
................................................13
EMFWD Differential Oil ..........................
......13 Alternative Lubricants...................
................14 Synthetic Lubricants...........
..........................14 Lubricant Storage
.........................................14 Mixing
of Lubricants ...................................
..14 Oil Filters .................................
.....................14 Brake Fluid
..................................................
.14 Chassis Grease................................
............14 Coolant ...........................
.................................15 Recommended
Engine Coolant ...................15 Serial
Number Locations ...............................15
Product Serial Number ...........................
......15
Specifications and Information
Table of Contents - 5
9
SPECIFICATIONS AND INFORMATION GENERAL
INFORMATION General Information Metric Fastener
Torque Values
Property Class and Head Markings 4.8 4.8 4.8 4.8 4.8 4.8 8.8 8.8 8.8 9.8 9.8 9.8 10.9 10.9 10.9 10.9 10.9 10.9 12.9 12.9 12.9 12.9
Property Class and Nut Markings 5 5 10 10 10 10 12 12 12
MIF (TS1163)
Class 4.8 Class 4.8 Class 4.8 Class 4.8 Class 8.8 or 9.8 Class 8.8 or 9.8 Class 8.8 or 9.8 Class 8.8 or 9.8 Class 10.9 Class 10.9 Class 10.9 Class 10.9 Class 12.9 Class 12.9 Class 12.9 Class 12.9
Lubricated1 Lubricated1 Drya Drya Lubricateda Lubricateda Drya Drya Lubricateda Lubricateda Drya Drya Lubricateda Lubricateda Drya Drya
SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
1. Lubricated means coated with a lubricant
such as engine oil, or fasteners with phosphate
and oil coatings. Dry means plain or zinc
plated (yellow dichromate - Specification JDS117)
without any lubrication.
DO NOT use these hand torque values if a
different torque value or tightening procedure is
given for a specific application. Torque values
listed are for general use only and include a
10 variance factor. Check tightness of
fasteners periodically. DO NOT use air powered
wrenches. Shear bolts are designed to fail under
predetermined loads. Always replace shear bolts
with identical grade. Fasteners should be
replaced with the same class. Make sure fastener
threads are clean and that you properly start
thread engagement. This will prevent them from
failing when tightening. When bolt and nut
combination fasteners are used, torque values
should be applied to the NUT instead of the bolt
head. Tighten toothed or serrated-type lock nuts
to the full torque value. Reference JDS-G200.
10
SPECIFICATIONS AND INFORMATION
GENERAL INFORMATION
Inch Fastener Torque Values
SAE Grade and Head Markings No Marks 1 or 21 5 5.1 5.2 8 8.2
No Marks 2 5 8
SAE Grade and Nut Markings No Marks 2
MIF (TS1162)
Grade 1 Grade 1 Grade 1 Grade 1 Grade 21 Grade 21 Grade 21 Grade 21 Grade 5, 5.1 or 5.2 Grade 5, 5.1 or 5.2 Grade 5, 5.1 or 5.2 Grade 5, 5.1 or 5.2 Grade 8 or 8.2 Grade 8 or 8.2 Grade 8 or 8.2 Grade 8 or 8.2
Lubricated2 Lubricated2 Dry2 Dry2 Lubricated2 Lubricated2 Dry2 Dry2 Lubricated2 Lubricated2 Dry2 Dry2 Lubricated2 Lubricated2 Dry2 Dry2
SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

1. Grade 2 applies for hex cap screws (not hex
   bolts) up to 152 mm (6 in.) long. Grade 1
   applies for hex cap screws over 152 mm (6 in.)
   long, and for all other types of bolts and screws
   of any length.
2. Lubricated means coated with a lubricant such
   as engine oil, or fasteners with phosphate and
   oil coatings. Dry means plain or zinc plated
   (yellow dichromate - Specification JDS117)
   without any lubrication.

DO NOT use these hand torque values if a
different torque value or tightening procedure is
given for a specific application. Torque values
listed are for general use only and include a
10 variance factor. Check tightness of
fasteners periodically. DO NOT use air powered
wrenches. Shear bolts are designed to fail under
predetermined loads. Always replace shear bolts
with identical grade. Fasteners should be
replaced with the same grade. Make sure fastener
threads are clean and that you properly start
thread engagement. This will prevent them from
failing when tightening. When bolt and nut
combination fasteners are used, torque values
should be applied to the NUT instead of the bolt
head. Tighten toothed or serrated-type locknuts
to the full torque value. Reference JDS-G200.
11
SPECIFICATIONS AND INFORMATION
GENERAL INFORMATION
Face Seal Fittings with Inch Stud Ends Torque
Stud End
Tube Nut
Straight Stud and Tube Nut
Swivel Nut
Locknut
Tube Nut
Stud End
90 Swivel Elbow and Tube Nut
90 Adjustable Stud Elbow
Bulkhead Union and Bulkhead Locknut MIF
Nominal Tube OD/Hose ID Nominal Tube OD/Hose ID Nominal Tube OD/Hose ID Nominal Tube OD/Hose ID Face Seal Tube/Hose End Face Seal Tube/Hose End Face Seal Tube/Hose End Face Seal Tube/Hose End Face Seal Tube/Hose End O-Ring Stud Ends O-Ring Stud Ends O-Ring Stud Ends
Metric Tube OD Inch Tube OD Inch Tube OD Inch Tube OD Thread Size Tube Nut/ Swivel Nut Torque Tube Nut/ Swivel Nut Torque Bulkhead Locknut Torque Bulkhead Locknut Torque Thread Size Straight Fitting or Locknut Torque Straight Fitting or Locknut Torque
mm Dash Size in. mm in. Nm lb-ft Nm lb-ft in. Nm lb-ft
-3 0.188 4.76 3/8-24 8 6
6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9
8 -5 0.312 7.94 1/2-20 16 12
10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18
12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34
16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46
-12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75
22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90
25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105
32 -20 1.25 31.75 1-11/16-12 190 140 190 140 1-5/8-12 190 140
38 -24 1.50 38.10 2-12 217 160 217 160 1-7/8-12 217 160
Note Torque tolerance is 15, -20.
12
SPECIFICATIONS AND INFORMATION
GENERAL INFORMATION
Face Seal Fittings with Metric Stud Ends Torque
Stud End
Tube Nut
Groove for Metric Identification Straight Stud
and Tube Nut
Swivel Nut
Locknut
Tube Nut
Groove for Metric Identification
Stud End
90 Swivel Elbow and Tube Nut
90 Adjustable Stud Elbow
Bulkhead Union and Bulkhead Locknut MIF
Nominal Tube OD/Hose ID Nominal Tube OD/Hose ID Nominal Tube OD/Hose ID Nominal Tube OD/Hose ID Face Seal Tube/Hose End Face Seal Tube/Hose End Face Seal Tube/Hose End Face Seal Tube/Hose End Face Seal Tube/Hose End Face Seal Tube/Hose End O-Ring Stud Ends, Straight Fitting or Locknut O-Ring Stud Ends, Straight Fitting or Locknut O-Ring Stud Ends, Straight Fitting or Locknut O-Ring Stud Ends, Straight Fitting or Locknut O-Ring Stud Ends, Straight Fitting or Locknut O-Ring Stud Ends, Straight Fitting or Locknut
Metric Tube OD Inch Tube OD Inch Tube OD Inch Tube OD Thread Size Hex Size Tube Nut/ Swivel Nut Torque Tube Nut/ Swivel Nut Torque Bulkhead Locknut Torque Bulkhead Locknut Torque Thread Size Hex Size Steel or Gray Iron Torque Steel or Gray Iron Torque Aluminum Torque Aluminum Torque
mm Dash Size in. mm in. mm Nm lb-ft Nm lb-ft mm mm Nm lb-ft Nm lb-ft
6 -4 0.250 6.35 9/16-18 17 16 12 12 9 M12x1.5 17 21 15.5 9 6.6
8 -5 0.312 7.94
M14x1.5 19 33 24 15 11
10 -6 0.375 9.52 11/16-16 22 24 18 24 18 M16x1.5 22 41 30 18 13
12 -8 0.500 12.70 13/16-16 24 50 37 46 34 M18x1.5 24 50 37 21 15
16 -10 0.625 15.88 1-14 30 69 51 62 46 M22x1.5 27 69 51 28 21
-12 0.750 19.05 1-3/16-12 36 102 75 102 75 M27x2 32 102 75 46 34
22 -14 0.875 22.22 1-3/16-12 36 102 75 102 75 M30x2 36
25 -16 1.000 25.40 1-7/16-12 41 142 105 142 105 M33x2 41 158 116 71 52
28 M38x2 46 176 130 79 58
32 -20 1.25 31.75 1-11/16-12 50 190 140 190 140 M42x2 50 190 140 85 63
38 -24 1.50 38.10 2-12 60 217 160 217 160 M48x2 55 217 160 98 72
Note Torque tolerance is 15, -20.
13
SPECIFICATIONS AND INFORMATION
GENERAL INFORMATION
O-Ring Face Seal Fittings
A B A
A C B
MIF
MIF

1. For angle fittings, loosen special nut (A) and
   push special washer (B) against threads so O-ring
   can be installed into the groove of fitting.
2. Turn fitting into the boss by hand until special
   washer or washer face (straight fitting) contacts
   boss face and O-ring is squeezed into its seat.
3. To position angle fittings (C), turn the fitting
   counter- clockwise a maximum of one turn.
4. Tighten straight fittings to torque value shown
   on chart. For angle fittings, tighten the special
   nut to value shown on the chart while holding
   body of fitting with a wrench.

1. Inspect the fitting sealing surfaces (A). They
   must be free of dirt or defects.
2. Inspect the O-ring (B). It must be free of damage
   or defects.
3. Lubricate O-rings and install into groove using
   petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of
   petroleum jelly so O-ring is not displaced during
   assembly.
5. Index angle fittings and tighten by hand-pressing
   joint together to ensure O-ring remains in place.

Thread Size Torque1 Torque1 Number of Flats2
Thread Size Nm lb-ft Number of Flats2
3/8-24 UNF 8 6 2
7/16-20 UNF 12 9 2
1/2-20 UNF 16 12 2
9/16-18 UNF 24 18 2
3/4-16 UNF 46 34 2
7/8-14 UNF 62 46 1-1/2
1-1/16-12 UN 102 75 1
1-3/16-12 UN 122 90 1
1-5/16-12 UN 142 105 3/4
1-5/8-12 UN 190 140 3/4
1-7/8-12 UN 217 160 1/2
Important Avoid Damage! DO NOT allow hoses to
twist when tightening fittings. Use two wrenches
to tighten hose connections one to hold the
hose, and the other to tighten the swivel fitting.
6. Tighten fitting or nut to torque value shown
on the chart per dash size stamped on the
fitting. O-Ring Boss Fittings 1. Inspect O-ring
boss seat. It must be free of dirt and defects.
If repeated leaks occur, inspect for defects with
a magnifying glass. Some raised defects can be
removed with a slip stone.
B
A

• Torque tolerance is 10 percent.
• To be used if a torque wrench cannot be used.
  After tightening fitting by hand, put a mark on
  nut or boss, then tighten special nut or straight
  fitting the number of flats shown.
• MIF
• 2. Put hydraulic oil or petroleum jelly on the
  O-ring (A). Place electrical tape over the
  threads to protect O-ring from nicks. Slide
  O-ring over the tape and into the groove (B) of
  fitting. Remove tape.

14
SPECIFICATIONS AND INFORMATION GENERAL
INFORMATION Diesel Fuel Diesel Fuel Storage
Caution Avoid Injury! California Proposition 65
Warning Diesel engine exhaust and some of its
elements from this product are known to the State
of California to cause cancer, birth defects, or
other reproductive harm.
Important Avoid Damage! DO NOT USE GALVANIZED
CONTAINERS - diesel fuel stored in galvanized
containers reacts with zinc coating in the
container to form zinc flakes. If fuel contains
water, a zinc gel will also form. The gel and
flakes will quickly plug fuel filters and damage
fuel injectors and fuel pumps.

• In general, diesel fuels are blended to satisfy
  the low air temperature requirements of the
  geographical area in which they are sold.
• In North America, diesel fuel is usually
  specified to ASTM D975 and sold as either Grade 1
  for cold air temperatures or Grade 2 for warm air
  temperatures.
• If diesel fuels being supplied in your area DO
  NOT meet any of the above specifications, use
  diesel fuels with the following equivalent
  properties
• Cetane Number 40 (minimum)
• A cetane number greater than 50 is preferred,
  especially for air temperatures below -20C
  (-4F) or elevations above 1500 m (5000 ft).
• Cold Filter Plugging Point (CFPP)
• The air temperature at which diesel fuel begins
  to cloud or jell - at least 5C (9F) below the
  expected low air temperature range.
• Sulfur Content of 0.05 (maximum)
• Diesel fuels for highway use in the United States
  now require sulfur content to be less than 0.05.
• If diesel fuel being used has a sulfur content
  greater than 0.05, reduce the service interval
  for engine oil and filter by 50.
• Consult your local diesel fuel distributor for
  properties of the diesel fuel available in your
  area.

It is recommended that diesel fuel be stored ONLY
in a clean, approved POLYETHYLENE PLASTIC
container WITHOUT any metal screen or filter.
This will help prevent any accidental sparks from
occurring. Store fuel in an area that is well
ventilated to prevent possible igniting of fumes
by an open flame or spark, this includes any
appliance with a pilot light.
Important Avoid Damage! Keep all dirt, scale,
water or other foreign material out of fuel.
Keep fuel in a safe, protected area and in a
clean, properly marked (DIESEL FUEL) container.
DO NOT use de-icers to attempt to remove water
from fuel. DO NOT depend on fuel filters to
remove water from fuel. It is recommended that a
water separator be installed in the storage tank
outlet. BE SURE to properly discard unstable or
contaminated diesel fuel and/or their containers
when necessary.

• 4 - Cycle Diesel Engine Oil
• Use the appropriate oil viscosity based on the
  expected air temperature range during the period
  between recommended oil changes. Operating
  outside of these recommended oil air temperature
  ranges may cause premature engine failure.
• The following John Deere oils are PREFERRED
  TORQ-GARD SUPREMETM
• PLUS-50TM
• Other oils may be used if above John Deere oils
  are not available, provided they meet one of the
  following specifications
• API Service Classifications CF - 4 or higher

Diesel Fuel Lubricity Diesel fuel must have
adequate lubricity to ensure proper operation and
durability of fuel injection system components.
Fuel lubricity should pass a minimum of 3300 gram
load level as measured by the BOCLE scuffing test.
Important Avoid Damage! If diesel fuel with
sulfur content greater than 0.5 is used, reduce
the service interval for oil and filter by 50.
15
SPECIFICATIONS AND INFORMATION GENERAL INFORMATION
Transaxle Oil Use the appropriate oil viscosity
based on these air temperature ranges. Operating
outside of these recommended oil air temperature
ranges may cause premature hydrostatic
transmission or hydraulic system failures.
SAE 10W-40 SAE 10W-30 SAE 5W-30
Important Avoid Damage! Mixing of LOW VISCOSITY
HY - GARD and HY - GARD oils is permitted. DO
NOT mix any other oils in this transmission. DO
NOT use engine oil or Type F (Red) Automatic
Transmission Fluid in this transmission.
50 68 86 104 122 10 20 30 40 50
-40 -22 -4 14 -40 -30 -20 -10
32F
0 C
Break-In Engine Oil - Diesel

• John Deere J20C HY-GARD transmission and
  hydraulic oil is recommended. John Deere J20D Low
  Viscosity HY- GARD transmission and hydraulic
  oil may be used, if within the specified
  temperature range.
• Other oils may be used if above recommended John
  Deere oils are not available, provided they meet
  one of the following specifications
• John Deere Standard JDM J20C
• John Deere Standard JDM J20D.

Important Avoid Damage! ONLY use this specified
break-in oil in rebuilt or remanufactured engines
for the first 100 hours (maximum) of operation.
DO NOT use PLUS - 50, SAE 15W40 oil or oils
meeting specifications API CG - 4 or API CF - 4,
these oils will not allow rebuilt or
remanufactured engines to break-in properly.

• The following John Deere oil is PREFERRED
• BREAK - IN ENGINE OIL.
• John Deere BREAK - IN ENGINE OIL is formulated
  with special additives for aluminum and cast iron
  type engines to allow the power cylinder
  components (pistons, rings, and liners as well)
  to wear-in while protecting other engine
  components, valve train and gears, from abnormal
  wear. Engine rebuild instructions should be
  followed closely to determine if special
  requirements are necessary.
• John Deere BREAK - IN ENGINE OIL is also
  recommended for non-John Deere engines, both
  aluminum and cast iron types.
• If this preferred John Deere oil is not
  available, use a break- in engine oil meeting the
  following specification during the first 100
  hours of operation
• API Service Classification CE or higher.

HY-GARD J20C
-40 -22 -4 14 50 68 86 104 122
32 F
-40 -30 -20 -10 0 C 10 20 30 40 50 Low Viscosity
HY-GARD J20D BIO-HY-GARD
EMFWD Differential Oil John Deere J20D Low
Viscosity HY-GARD transmission and hydraulic oil
is recommended.
Important Avoid Damage! After the break-in
period, use the John Deere oil that is
recommended for this engine.
Important Avoid Damage! Mixing of LOW VISCOSITY
HY - GARD and HY - GARD oils is permitted. DO
NOT mix any other oils in this transmission. DO
NOT use engine oil or Type F (Red) Automatic
Transmission Fluid in this transmission.
BREAK-IN OIL

• Other oils may be used if above recommended John
  Deere oils are not available, provided they meet
  the following specification
• John Deere Standard JDM J20D.

-40 -22 -4 14 50 68 86 104 122
32 F
-40 -30 -20 -10 0 C 10 20 30 40 50
16
SPECIFICATIONS AND INFORMATION GENERAL INFORMATION

• drainback valves for better engine protection.
• Other oil filters may be used if above
  recommended John Deere oil filters are not
  available, provided they meet the following
  specification
• ASTB Tested In Accordance With SAE J806.

Alternative Lubricants Use of alternative
lubricants could cause reduced life of the
component. If alternative lubricants are to be
used, it is recommended that the factory fill be
thoroughly removed before switching to any
alternative lubricant.

• Brake Fluid
• The following John Deere heavy duty brake fluid
  is PREFERRED for all drum and disc brakes
• Brake Fluid - DOT3
• Other brake fluids may be used if the above John
  Deere brake fluid is not available and they
  provide the following

Synthetic Lubricants Synthetic lubricants may be
used in John Deere equipment if they meet the
applicable performance requirements (industry
classification and/or military specification) as
shown in this manual. The recommended air
temperature limits and service or lubricant
change intervals should be maintained as shown in
the operators manual, unless otherwise stated on
lubricant label. Avoid mixing different brands,
grades, or types of oil. Oil manufacturers blend
additives in their oils to meet certain
specifications and performance requirements.
Mixing different oils can interfere with the
proper functioning of these additives and degrade
lubricant performance.

• DOT3 certified.
• Conforms to Motor Vehicle Safety Standard No.
  116.
• Minimum wet boiling point 140C (284F).
• Minimum dry boiling point 232C (450F) to prevent

vapor lock.
Chassis Grease Use the following grease based on
the air temperature range. Operating outside of
the recommended grease air temperature range may
cause premature failures. The following John
Deere grease is PREFERRED
Lubricant Storage All machines operate at top
efficiency only when clean lubricants are used.
Use clean storage containers to handle all
lubricants. Store them in an area protected from
dust, moisture, and other contamination. Store
drums on their sides. Make sure all containers
are properly marked as to their contents. Dispose
of all old, used containers and their contents
properly.

• Multi-Purpose SD Polyurea Grease
• Multi-Purpose HD Lithium Complex Grease
• Moly High-Temperature EP Grease

• Other greases may be used if above preferred John
  Deere grease is not available, provided they meet
  the following specification
• John Deere Standard JDM J13E4, NLGI Grade 2.

Mixing of Lubricants In general, avoid mixing
different brands or types of lubricants.
Manufacturers blend additives in their lubricants
to meet certain specifications and performance
requirements. Mixing different lubricants can
interfere with the proper functioning of these
additives and lubricant properties which will
downgrade their intended specified performance.
Oil Filters
Important Avoid Damage! Filtration of oils is
critical to proper lubrication performance. Always
change filters regularly.

• The following John Deere oil filters are
  PREFERRED
• AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL FILTERS.
• Most John Deere filters contain pressure relief
  and anti-

17
SPECIFICATIONS AND INFORMATION COOLANT Serial
Number Locations
Coolant
Recommended Engine Coolant Product Serial Number

• Important Avoid Damage! Using incorrect coolant
  mixture can cause overheating and damage to the
  radiator and engine
• Do not operate engine with plain water.
• Do not exceed a 50 mixture of coolant and
• water.
• Aluminum engine blocks and radiators require
• approved ethylene-glycol based coolant.

A
The engine cooling system is filled to provide
year-round protection against corrosion and
cylinder liner pitting, and winter freeze
protection to -37 degrees C (-34 degrees F). If
protection at lower temperatures is required,
consult your John Deere dealer for
recommendations.
MX44978
The 13-digit product identification number (A) is
located on the right-hand side frame. Engine
serial number (A) is located on the valve cover.
The following coolants are preferred

• John Deere COOL-GARD II Premix
• John Deere COOL-GARD Premix
• John Deere COOL-GARD PG Premix

• John Deere COOL-GARD II Premix and John Deere
  COOL-GARD Premix are available in a concentration
  of 50 propylene glycol.
• John Deere COOL-GARD PG Premix is available in a
  concentration of 55 propylene glycol.
• Additional recommended coolants
• John Deere COOL-GARD II Concentrate in a 40 to
  60 mixture of concentrate with water.
• John Deere COOL-GARD Concentrate in a 40 to 60
  mixture of concentrate with water.
• If the recommended coolants are unavailable, use
  an ethylene glycol or propylene glycol base
  coolant that meets the following specification
• ASTM D3306 prediluted (50) coolant.
• ASTM D3306 coolant concentrate in a 40 to 60
  mixture of concentrate with water.
• Check container label before using to be sure it
  has the appropriate specifications for your
  machine. Use coolant with conditioner or add
  conditioner to coolant before using.
• Water Quality
• Water quality is important to the performance of
  the cooling system. Distilled, deionized, or
  demineralized water is recommended with ethylene
  glycol base engine coolant concentrate.

Specifications and Information
Coolant - 15
18
ENGINE - DIESEL
TABLE OF CONTENTS
Engine Oil Pressure Test..........................
... 50 Fuel Injection System Tests................
......... 51 Fuel Injection Nozzle Test
........................... 52 Injection Pump
Timing ................................ 54
Injection Pump Static Timing Check............ 54
Fuel System Air Bleeding .........................
... 56 Fuel Transfer Pump Flow Test
.................... 56 Fuel Transfer Pump
Pressure Test.............. 57 Repair
..................................................
............ 57 Engine Removal and Installation
................. 57 Muffler Removal and
Installation ................. 61 Exhaust
Manifold Removal and Installation. 62 Rocker Arm
Cover Removal and Installation ...................
................................ 62 Rocker Arm
and Push Rods ........................ 64
Cylinder Head Removal and Installation...... 66
Cylinder Head Recondition.........................
. 67 Crankshaft Rear Oil Seal.....................
........ 72 Crankshaft Front Oil Seal
........................... 73 Timing Gear Cover
......................................
74 Camshaft End Play Check........................
... 75 Timing Gear Backlash Check
...................... 75 Idler
Gear..............................................
....... 76 Cam Followers..........................
................... 77 Camshaft
..................................................
... 78 Oil Pan and Strainer ......................
............. 81 Connecting Rod Side Play
Check................ 81 Crankshaft End Play
Check ........................ 82 Connecting Rod
Bearing Clearance Check. 82 Crankshaft Main
Bearing Clearance Check. 83 Connecting Rod Repair
............................... 84
Pistons...........................................
.............. 86 Cylinder Bore...................
............................ 90 Crankshaft and
Main Bearings .................... 91 Flywheel
Removal and Installation .............. 94
Flywheel Plate ...................................
.......... 95 Timing Gear Housing.................
.................. 95 Oil Pump Removal and
Installation.............. 96 Coolant Temperature
Switch ....................... 97 Thermostat
Removal and Installation .......... 97 Water Pump
Removal and Installation ........ 98 Fuel Filter
Removal and Installation ............ 99 Fuel
Filter Assembly Removal and Installation..........
........................................
100 Fuel Filter Components .......................
...... 100 Fuel Transfer Pump ....................
.............. 101 Fuel Injection Nozzle
................................. 101 Fuel
Injection Pump...................................
104
Table of Contents
Specifications ...................................
.............19 Engine Specifications
...................................19 Operational
Tests .........................................19
Tests and Adjustment Specifications ...........20
Repair Specifications.............................
.......20 Tightening Torques .....................
.................24 Special or Essential Tools
............................25 Other
Materials.........................................
....25 Component Location.........................
.............26 Engine Fuel System
.....................................26 Engine
Mounts ...........................................
..27 Fuel System Components.......................
.....28 Exhaust System Components.................
.....29 Coolant System Components.................
......30 Theory of Operation .....................
..................32 Cooling System Theory of
Operation ...........32 Lubrication System Theory
of Operation......33 Fuel System Theory of
Operation ................34 Air System Theory of
Operation ...................35 Diagnostics
..................................................
...35 Engine Troubleshooting and
Diagnostics.....35 System Engine
Oil.......................................35 Sympt
om Excessive Fuel Consumption......36 Symptom
Incorrect Manifold Pressure ........36 Symptom
Low Engine Compression ...........36 Symptom
Engine Starting Problem .............37 Symptom
Engine Operation Poor................38 Symptom
Coolant Temperature Abnormal..40 Symptom Coolant
in Oil or Oil in Coolant....41 System
Diagnostics.....................................41
Tests and Adjustments ...........................
.......43 Air Restriction Indicator Test
........................43 Fast Idle Speed
Adjustment .........................44 Slow Idle
Adjustment....................................44 T
hrottle Cable Adjustment..........................
..45 Valve Clearance Adjustment
........................46 Valve Lift Check
...........................................47 Cyli
nder Compression Test ..........................47
Water Pump/Alternator Drive Belt Adjustment
..................................................
.48 Thermostat Test ..............................
.............49 Radiator Bubble
Test....................................49 Cooling
System Pressure Test.....................50 Radia
tor Cap Pressure Test.........................50
19
ENGINE - DIESEL
TABLE OF CONTENTS
Fuel Control and Governor Linkage ...........106
Fuel Shutoff Solenoid Removal and Installation
..................................................
107 Starting Motor Removal and Installation
....107 Alternator Removal and Installation
...........108
20
ENGINE - DIESEL
SPECIFICATIONS
Specifications Engine Specifications General
Specifications Make. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
Yanmar Model . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
3TNV70 Injection Type . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . Indirect Type . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 4-Cycle Diesel Number of Cylinders . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 3 Bore
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 70 mm (2.76 in.) Stroke . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 74 mm (2.91
in.) Displacement . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
0.854 L (52.11 cu in.) Firing Order. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 1 -
3 - 2 Direction of Rotation . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Counterclockwise (viewed from
flywheel) Combustion System. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
Indirect Injection Type Compression Ratio. . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 23.4
1 Cooling . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . Liquid Oil Capacity
(w/filter) . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 2.6
L (2.75 qt) Governor . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . Centrifugal Slow
Idle (no-load) . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 1050 25 rpm High Idle (no-load) . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 3700 25
rpm Operational Tests Specifications Cylinder
Compression Pressure (_at_250 RPM Cranking Speed). .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 3432 kPa (498 psi) (Minimum) . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 2746 kPa (398
psi) Difference Between Cylinders. . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
245 kPa (36 psi) Cooling System Coolant Capacity
(approximate) . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 5.0 L (5.2
qt) Radiator Cap Opening Pressure . . . . . . . .
. . . . . . . . . . . . . . . . . . . 0.9 0.15
kg/cm2, 88.3 14.7 kPa, (12.8 2.2 psi) Cooling
System Pressure Test . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 0.9 0.15 kg/cm2,
88.3 14.7 kPa, (12.8 2.2 psi) Thermostat
Opening Temperature . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 69.5 - 72.5 C (157 - 163 F) Thermostat
Minimum Lift Height above 85 C (185 F) . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 8 mm (0.315 in.) Oil
Pressure Rated Speed . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
290 - 440 kPa (42 - 63 psi) Slow Idle (Minimum) .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 60 kPa (9
psi) Oil Pressure Switch Opening Pressure . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 3 - 4 kPa (6
- 9 psi)
Engine - Diesel Specifications - 19
21
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22
ENGINE - DIESEL SPECIFICATIONS Tests and
Adjustment Specifications Specifications Valve
Clearance . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 0.15 - 0.25 mm (0.006 - 0.010
in.) Connecting Rod Side Play . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 0.2 - 0.4 mm (0.008 -
0.016 in.) Connecting Rod Bearing Clearance . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 0.02 - 0.05 mm (0.001 -
0.002 in.) Crankshaft End Play. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 0.11 - 0.25 mm
(0.004 - 0.009 in.) Crankshaft Main Bearing
Clearance . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 0.02 - 0.05
mm (0.001 - 0.002 in.) Camshaft End Play . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
0.05 - 0.15 mm (0.002 - 0.006 in.) Alternator
Drive Belt Deflection (_at_98 N (22 lb) Applied
Force) . . . . . . . . . . . . . . . . . . . . .
. . . 10 - 15 mm (0.4 - 0.6 in.) Fuel Injection
Nozzle Opening Pressure. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 12300 - 13300 kPa (1784
- 1929 psi) Leakage at 11032 kPa (1600 psi) . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .None for a minimum of 5
seconds Chatter and Spray Pattern at 12300 -
13300 kPa (1784 - 1929 psi) Slow Hand Lever
Movement . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . Chatter
Sound Repair Specifications Valve Train Rocker
Arm Shaft OD. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 11.97 - 11.98 mm (0.471 - 0.472
in.) Wear Limit . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11.94 mm (0.470 in.) Rocker Arm and Shaft
Support Bushings ID . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 12.00 - 12.02 mm
(0.472 - 0.473 in.) Wear Limit . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 12.07 mm (0.475 in.) Oil
Clearance. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 0.02 - 0.05 mm (0.001 -
0.002 in.) Wear Limit . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 0.13 mm (0.005 in.) Push Rod Bend
(maximum). . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 0.0 - 0.03 mm (0.0 - 0.001 in.) Cylinder
Head Cylinder Head Flatness . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 0.000 - 0.05 mm (0.000
- 0.002 in.) Service Limit . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 0.15 mm (0.006 in.) Valve Seat
Angles Exhaust Valve . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 45 Intake
Valve . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 30 Lower Seat Surface .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 70 Upper Seat Surface . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 15 Intake Valve
Head Margin . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 0.9 - 1.1 mm (0.035 - 0.043
in.) Exhaust Valve Head Margin. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 1.0 - 1.2 mm (0.039 -
0.047 in.) Wear Limit . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 0.50 mm (0.02 in.) Valve
Recession Intake and Exhaust . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 0.40 - 0.60
mm (0.016 - 0.024 in.) Wear Limit Intake . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 0.9 mm (0.035 in.) Wear
Limit Exhaust . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 0.8 mm
(0.031 in.) Valve Stem Diameter Intake . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 5.96 - 5.98 mm (0.234 - 0.235
in.) Exhaust . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 5.95 - 5.96
mm (0.234 - 0.235 in.) Engine - Diesel
Specifications - 20
23
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